Method and apparatus for forming delivery devices for oral intake of an agent

ABSTRACT

Methods, systems and apparatuses are provided for producing delivery devices, preferably for oral intake of an agent. In the broadest aspect, the method comprises assembling one or more layers comprising one or more materials with an agent or an agent-releasing formulation to form an intergraded, preferably laminated device; folding said integrated delivery device to form a folded integrated delivery device; and at least partially enclosing said folded delivery device to a form suitable for oral delivery. Preferably, the integrated device comprise a first external layer of a first material; a frame of a second material mounted on the first external layer; an agent-releasing formulation housed within the frame; and a second external layer of the first material mounted on the frame.

FIELD OF THE INVENTION

This invention relates generally to methods and apparatuses for formingdelivery systems for the controlled release of active agents and morepreferably for forming delivery system with gastroretentivity.

BACKGROUND OF THE INVENTION

Many controlled release dosage forms have been developed for thedelivery of pharmaceutical drugs for prolonging the release andabsorption of the drug in the alimentary canal. Similarly, many methodsand types of apparatus have been invented to produce such drugs. Forexample, U.S. Pat. No. 5,472,710 to Klokkers-Bethke et al., discloses apharmaceutical preparation to be administered orally with controlledrelease of an active substance and a method for the manufacture of thepreparation.

U.S. Pat. No. 6,669,954 to Crison et al., discloses devices forcontrolled release of drugs.

U.S. Pat. No. 6,685,962, to Friedman et al., discloses gastro-retentivecontrolled release pharmaceutical dosage forms.

U.S. Pat. No. 6,911,217 to Gren et al., discloses a controlled releasebead, a method for producing the same and a multiple unit formulationcomprising the bead.

WO 03/105812 A1 describes an extruded pharmaceutical product forretention in the stomach; comprising a sheet of hydratable polymer of asize that does not exit the stomach; a shaped sheet; a planar sheet thatis rolled or folded or otherwise compacted; and a sealed hollow tubularextrudate.

WO 2005/009199 describes an automated process and apparatus for making agastro retentive device, having a pouch assembly or capsule assembly.

Despite the numerous advances in the development of controlled releasedelivery formulations, there is a still a need to develop apparatus andmethods for reliable mass production of agent delivery formulations.

SUMMARY OF THE INVENTION

The present invention provides, in accordance with a first of itsaspects, a method for producing an agent delivery device for oralintake, the method comprising:

-   -   (i) assembling one or more layers comprising one or more        materials with an agent or an agent-releasing formulation to        form an intergraded device;    -   (ii) folding said integrated delivery device to form a folded        integrated delivery device; and    -   (iii) at least partially enclosing said folded delivery device        to a form suitable for oral delivery.

The delivery device may be a single layer device or a multi-layereddevice. The layers are preferably made of a polymeric composition, eachlayer comprising a single polymer or a combination of polymers, and thecomposition of polymers in one layer may be the same or different fromthat of other layers in the device. The layers may also be divided intocompartments of the same or different constituents.

The invention also provides, in accordance with a second of its aspects,an agent delivery device for oral intake comprising a folded single ormulti-layered integrated device comprising the agent or agent releasingformulation, the folded integrated device being at least partiallyenclosed within or by an enclosure, whenever the device is produced bythe method of the invention. The oral delivery device serves as aplatform for the delivery of any agent, the oral intake of which isrequired. The various applications will be dictated by the agentselected, the type of polymers selected, the type of enclosure etc, etc.

The agent, which as will be further described hereinbelow, may be fororal intake either for purposes of therapy (e.g. a drug), diagnostics(e.g. a contrasting agent), or for a subject's general health (e.g. anutrient). It is preferable that the agent be releasable from thedevice.

Due to the characteristic features of the integrated device obtained inaccordance with the invention, the release of the agent from the device,once wetted by gastric medium, is in a controlled, while being retainedin the gastrointestinal tract.

The invention also provides, in accordance with a third aspect, a systemfor producing an agent-delivery device for oral intake, the systemcomprising:

-   -   (i) an assembly apparatus adapted to assemble one or more layers        comprising one or more materials and an agent or an        agent-releasing formulation to form an intergraded device        comprising said agent or agent-releasing formulation;    -   (ii) a folding apparatus adapted to fold the integrated device        into a folded integrated device; and    -   (iii) an enclosing apparatus adapted to at least partially        enclose the folded integrated device within an enclosure to form        a device in a form suitable for oral delivery.

It is to be noted that the invention also provides a folding apparatusper se, for folding a single or multi-layered sheet which may be thesame or different from those defined herein. The folding apparatus,according to this aspect of the invention comprises a primary press withtwo opposite faces, each face having a corrugated surface with ridges ofone corrugated surface being essentially opposite to troughs of theother corrugated surface and essentially fitting one into the other;whereby upon placing at least a portion of the single or multi-layeredsheet in the press and pressing the two opposite faces one versus theother a three dimensional device having at least said portion undulatedis formed with undulations that correspond in shape to that of saidcorrugated surfaces. The folding apparatus may comprise a secondarypress comprising opposite faces perpendicular to the faces of saidprimary press and adapted to press the undulated device so as to form amore compacted folded device having a dimension which is preferably atleast five times smaller than that of the sheet prior to pressing.

With respect to the folding apparatus there is thus also provided amethod for folding a single or multi-layered sheet comprising:

-   -   (i) placing said single or multi-layered sheet in a folding        apparatus in accordance with the invention;    -   (ii) pressing two opposite faces of the press one versus the        other to form an undulated, three dimensional device with        undulations that correspond in shape to that of said corrugated        surfaces; and    -   (iii) optionally, pressing two opposite faces perpendicular to        the direction of press applied in step (ii).

BRIEF DESCRIPTION OF THE DRAWINGS

In order to understand the invention and to see how it may be carriedout in practice, a preferred embodiment will now be described, by way ofnon-limiting example only, with reference to the accompanying drawings,in which:

FIG. 1A is a simplified flowchart illustrating the major process stepsof a method for producing a compacted agent delivery device inaccordance with an embodiment of the present invention;

FIG. 1B is a simplified flowchart illustrating a method for producing anencapsulated folded dosage form in accordance with a preferredembodiment of the present invention;

FIG. 2 is a simplified flowchart illustrating details of a dicing stepof FIG. 1B;

FIG. 3 is a simplified flowchart illustrating details of a powderingstep of FIG. 1B;

FIG. 4 is a schematic pictorial illustration of the main steps of themethod of FIG. 1B;

FIG. 5 is a simplified perspective view of an apparatus for dicing andassembling layers into an integrated device in accordance with apreferred embodiment of the present invention;

FIG. 6A is a simplified perspective view of an apparatus for powderingan integrated device in accordance with a preferred embodiment of thepresent invention;

FIG. 6B is a simplified perspective view of a sliding board forming partof the system for powdering of FIG. 6A;

FIG. 7A is a simplified perspective view of an apparatus for folding adevice, in accordance with a preferred embodiment of the presentinvention;

FIG. 7B is a simplified perspective view of an apparatus for inserting afolded device in to a capsule, in accordance with a preferred embodimentof the present invention;

FIG. 8 is a simplified side view of an upper face of a press formingpart of an apparatus for folding an integrated device in accordance witha preferred embodiment of the invention;

FIG. 9 is a simplified side view of two faces of a press whilesandwiching a laminated device in accordance with another preferredembodiment of the invention;

FIG. 10 is a simplified perspective view of a push block integratingbetween the folding apparatus and encapsulating apparatus, in accordancewith a preferred embodiment of the invention;

FIG. 11A-11E show a side view of components (FIGS. 12A-12D) of anessentially planar oval delivery device and the integrated device (FIG.12E) with pores on the two external layers, produced by the method ofFIG. 1A, in accordance with a preferred embodiment of the presentinvention;

FIG. 12A-12E show a side view of components (FIGS. 13A-13D) of anessentially planar delivery device with the agent being incorporatedinto separate compartments (FIG. 13B) to form the integrated device(FIG. 13E) produced by the method of FIG. 1A, in accordance with anotherpreferred embodiment of the present invention;

FIG. 13A-13B shows a side and cross-sectional view of an encapsulatedfolded delivery device produced by the method of FIG. 1A, in accordancewith a preferred embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION AND SOME NON-LIMITING EXEMPLARYEMBODIMENTS

The present invention is directed to methods and apparatuses forproducing agent delivery devices for oral intake and particularly tocompacted laminated gastro-retentive/controlled release dosage forms.The dosage forms typically comprise at least one active agent which isphysically retained within or on at least one compartment (section) orlayer of the device. The compartment may at least partially surround theagent, or entrap the agent or the agent may be embedded or adsorbed intoa layer, as will be further discussed hereinbelow. Additionally oralternatively, the agent may be bound chemically to one or morecompartments/layers of the device. The structure containing the agentmay be further surrounded by an at least partially enclosing frame so asto form a generally planar assembly. Sometimes the assembly will haveexternal layers affixed thereto so as to form a laminated device.

Glossary

In the following description and claims use will be made, at times, witha variety of terms, and the meaning of such terms as they should beconstrued in accordance with the invention is as follows:

By “an agent” is meant an entity, a substance or a chemical capable ofproducing an effect. The agent may be a pharmaceutical drug, asubstance, such as a contrasting agent to be used for diagnostic or, anutritional substance. As will be appreciated the invention is notlimited to any specific agent and generally it may be any agent that isadministered orally for either systemic effect or a local effect withinthe gastro-intestinal (GI) tract. The agent may be incorporated in thedelivery device in its active form or in a pro-active form, e.g. as apro-drug, such that only upon contact with body fluids (e.g. gastriccontent), it is converted to its active form.

By “an agent releasing formulation” is meant a formulation comprisingthe agent and at least one pharmaceutically acceptable carrier as wellas formulations in which the agent is attached (physical or chemicalattachment) to or in a nano- or microparticles, powder, liquid orcompressed solids or to a matrix. The agent-releasing formulation mayinclude other pharmaceutically acceptable excipients, as known to thoseversed in the pharmacy. In the following description the term agent andagent-releasing formulation may be used interchangeably to denote theagent either in a free form or as part of a formulation.

As used herein, “a drug” is meant for any substance used for thetreatment, or prevention of a disease, syndrome or a symptom, or to amedicament comprising an active component.

As used herein, “an integrated device” is meant for any dosage formhaving a structure composed of different parts which are united togetherin one functional and physical whole, to provide, under essentially dryconditions, a structurally stable unified form. A preferred form of anintegrated device in accordance with the invention is that wherein theone or more layers are laminated so as to form a laminated device.

As used herein, “laminated” is meant for a device comprising two or morelayers/sheets (which may be the same of different), physically ofchemically attached/bound together.

As used herein, “a laminated device” is meant for a device consisting oftwo or more separate layers/films joined together to form asubstantially flat plate or sheet, where the separate components stillremain in separate phases.

As used herein, “a folded device” is meant for a device that had beenmanipulated by one or more of folding about fold lines, bending,twisting, wrapping, winding, rolling, crimping and the like. Forexample, and without being limited thereto, folding may be parallel tothe width of the unfolded device and designed to have folds which aresymmetric mirror images about a first axis. This manner of folding mayprovides an accordion-like configuration for an originally essentiallyplanar device; or the folding may be such that the folded device hasfolds of increasingly smaller amplitudes upon extending away from thefirst axis so as to form a partially rounded cross section; yet, afurther example is of a folds of increasingly larger amplitudes uponextending away from one end of the first axis to its other end, so as toform a fan-like configuration. An example of a folded device isillustrated in FIG. 4.

As used herein, “a delivery device” is meant for any biocompatibledosage form for the delivery, preferably by oral intake, of an agent oran agent-releasing formulation. More specifically, the delivery devicecomprises the integrated/laminated device folded and enclosed within anenclosure. In the context of one preferred embodiment of the invention,the delivery device is a gastroretentive dosage form.

As used herein, “unfolded” is meant for an essentially and generallyplanar configuration of the device. The term “essentially planar” or“generally planar” denotes a fully planar as well as wiggly or wavyshape of the device. Unfolding denotes any form of expansion of thedevice, which may result form unwinding, unrolling, inflating, swelling,and the like. Following expansion in the stomach, the unfolded andessentially planar device maintains its firmness due to its uniquecharacteristics, as exemplified below

As used herein, “gastro-retentive” or “gastro-retentivity” is meant themaintenance or withholding of the agent carried by the delivery devicein the GI tract (either after being released from or still inassociation with one or more of the device's compartments/layers), for atime period longer than the time it would have been retained in thestomach when delivered in a free form or within a gastro-intestinaldelivery vehicle which is not considered gastro-retentive.Gastro-retentivity may be characterized by retention in the stomach fora period that is longer than the normal emptying time from the stomach,i.e. longer than about 2 hours, following an average meal, particularlylonger than about 3 hours and usually more than about 4, 6, 8 or 10hours. Gastroretentivity typically means retention in the stomach fromabout 3, 4, 6, 8 or at times 10 hours up to about 18 hours. It ishowever noted that in accordance with the invention, retention of thegastroretentive delivery device is not observed after more than 48 hoursafter administration, and preferably not after 24 hours.

As used herein, “controlled-release” is meant for a dosage form thatreleases the agent contained in it in a controlled rate, which isusually slowed down or delayed or accelerated as compared to the naturaldissolution rate of the agent in the liquid (typically aqueous) medium,e.g. the gastric fluid or simulated gastric fluid.

As used herein “enclosing” is meant for containing, especially so as toenvelop or shelter the device in a container. The container (sometimestermed herein “envelop” or “enclosure”) may be, without being limitedthereto, a capsule (soft or solid) containing the folded device, anelongated tube, a ring or a thread (one or more) surrounding the foldeddevice, a polymeric coating (e.g. a polymeric thread wrapping the devicein a manner resembling a cocoon), a polymer or gel matrix embedding thefolded device, enclosing by molding or pressing to a form of a tabletand the like.

As used herein, “coating” is meant for the application of a layer of asubstance to a surface for protection or modification of the externalproperties (such as adhesiveness) of the surface.

As used herein, “powdering” is meant for powder coating, e.g. byspreading of powder on a surface. The spreading of the powder may bepreceded with the application on the surface to be powdered withsuitable adhesive agents.

As used herein, “a polymer” or “polymeric composition” is meant for asingle or combination of polymers exemplified by, but not limited to,degradable polymers, non-degradable polymers, as well as a combinationof at least degradable polymer and at least one non-degradable. Apolymer may degraded in the stomach or in the intestine either throughits solubility, chemical degradation such as hydrolysis of esters orsolubilization in the gastric or the intestinal media, or throughdisintegration that is caused by the mechanical forces applied by thestomach on any solid content, or by a combination of both.

It is noted that as used in the specification and claims, the forms “a”,“an” and “the” include singular as well as plural references unless thecontext clearly dictates otherwise. For example, the term “an agent”denotes one or more agents being the same.

Further, as used herein, the term “comprising” is intended to mean thatthe methods, system or apparatuses of the invention may include therecited elements but not excluding other elements. The term “consistingessentially of” is used to define that the methods, system orapparatuses include the recited elements but exclude other elements thatmay have an essential significance on the structure and function of theresulting delivery device. For example, a delivery device consistingessentially of three laminated layers will not include or includeadditional layers. “Consisting of” shall thus mean excluding more thantrace elements of other components/layers. Embodiments defined by eachof these transition terms are within the scope of this invention.

Further, all numerical values, e.g. when referring the amounts or rangesof the components constituting the composition of the invention, areapproximations which are varied (+) or (−) by up to 20%, at times by upto 10% of from the stated values. It is to be understood, even if notalways explicitly stated that all numerical designations are preceded bythe term “about”.

According to one embodiment, the polymer soluble in gastric contentcomprises one or more polymers selected from a hydrogel-forming polymer,a non-hydrogel polymer, or any combination thereof. Non-limitingexamples of hydrogel-forming polymer comprise proteins, polysaccharides,including gums, gelatin, chitosan, polydextrose, cellulose derivatives,such as high molecular weight grades of hydroxypropyl cellulose,hypromelose, hydroxyethyl methyl cellulose, hydroxyethyl cellulose,methyl cellulose, polyethylene oxides, polyvinyl alcohols, solublederivatives of any one of the above as well as any combination of two ormore thereof. Non-limiting examples of non hydrogel polymer comprisepovidones (PVP), povidone, and vinyl acetate copolymers (copovidone),methacrylic acid copolymer with dimethyl amino ethyl methacrylate(Eudragit E™), low molecular weight grades of hydroxypropyl cellulose,propylene glycol alginate, polyethylene glycols, poloxamers and solublederivatives of any one of the above as well as any combination of two ormore thereof. These soluble polymers can be further cross-linked, eitherwith use of appropriate chemical cross-linking agent, or by physicalcross-linking techniques, or via exposure to gamma radiation, to controltheir mechanical properties and behavior upon contact with simulated andnatural gastric fluid.

According to another embodiment, the polymer may be a water insolublepolymer. A non-limiting list of polymers that are insoluble(non-degradable) comprises any polymer selected from a pharmaceuticallyacceptable enteric polymer, a pharmaceutically acceptable non-entericpolymer, or any combination thereof. An enteric polymer is preferablysuch that it is substantially insoluble at a pH of less than 5.5.Non-limiting examples of enteric polymers applicable with respect to theinvention include, shellac, cellacefate, hypromelose phthalate,hydroxypropyl methylcellulose acetate succinate, zein, polyvinyl acetatephthalate, aliginic acid and its salts, carboxymethyl cellulose and itssalts, methylmethacrylate-methacrylic acid copolymers, including ethylacrylate copolymers (polymethacrylates), or substantially insoluble (atpH of less than 5.5) derivatives of any one of the above as well as anyappropriate combination of two or more of the above. Non-limitingexamples of non-enteric polymers applicable with respect to theinvention include ethylcellulose; cellulose acetate; a copolymer ofacrylic acid and methacrylic acid esters, having of from about 5% toabout 10% functional quaternary ammonium groups; a polyethylene; apolyamide; a polyester; polyvinylchloride; polyvinyl acetate; and acombination of any two or more thereof.

This invention is directed to methods and apparatus for producing oraldelivery devices, particularly of gastroretentive delivery forms (GRDFs)and more particularly to encapsulated folded dosage forms.

Generally, the methods and apparatuses of the invention are directed toassembling dosage forms comprising an active agent, e.g. a drugcontained within a formulation or within one or more material layers,and one or more layers, which are typically in the form of a single orplurality of strips that have the purpose of imparting mechanicalstrength as will be explained below, the strips being typically, but notexclusively, arranged so as to define a continuous or non-continuousframe. In some preferred embodiments the device has one or two external,e.g. polymeric layers. For example, the agent-containing layer and theone or more strip are sandwiched between two layers, typically, the twoexternal layers.

Once the layers are assembled, the integrated or laminated deliverydevice is folded or compacted in some other way and thereafter at leastpartially enclosed in a container. Preferably the folded dosage form isencapsulated.

Thus, in accordance with its broadest aspects, the invention provides amethod producing an agent delivery device for oral intake, the methodcomprises the steps (preferably, however not exclusively, sequentialsteps) of assembling one or more layers comprising one or more materialswith an agent or an agent-releasing formulation to form an intergradeddevice; folding said integrated delivery device to form a foldedintegrated delivery device; and at least partially enclosing said foldeddelivery device to a form suitable for oral delivery.

In accordance with a preferred embodiment, the one or more layerscomprise one or more polymeric materials. Further, the one or morelayers may comprise a single polymer or a combination comprising two ormore polymers, the polymer or polymers in each layer may be the same ordifferent from that forming another layer in the device. The polymericmaterial may be a soluble polymer or soluble polymer combination (phdependent or pH independent) or a non-soluble polymer or a polymercombination, as defined hereinabove. The selection of polymercombinations for constituting each of the layers in the integrateddevice will be further explained hereinbelow.

In accordance with an embodiment of the present invention, the deliverydevice is formed from a folded integrated device that comprises twoexternal layers sandwiching a functional layer comprising the agent oragent-releasing formulation. In accordance with this embodiment, themethod comprises:

-   -   (a) assembling two external layers made of a first material so        as to sandwich a functional layer comprising one or more strips        made of a second material, the functional layer comprising one        or more agents in or on one or more compartments and/or layers,        respectively, of the functional layer;    -   (b) folding the integrated device into a folded integrated        device; and    -   (c) at least partially enclosing the folded integrated device.

In some preferred embodiments, the functional layer comprises a matrixfurther comprising one or more layers and the agent or agent-releasingformulation, said agent being releasable from the matrix. In someembodiments the matrix comprises a polymer or polymer combination thatis insoluble in gastric content. In some other embodiments, thefunctional layer may comprise a combination of compartments enclosing anagent formulation and a matrix embedding the active agent. The agentwithin the compartments and the agent embedded in the matrix may be thesame or different.

In some other embodiments, the matrix comprises at least one solublepolymer or a soluble combination of polymers in combination with atleast one insoluble polymer (or insoluble combination of polymers).

It is preferable that the agent or agent-releasing formulation isreleasable from the functional layer.

The one or more layers may also comprise a layer of an enforcingpolymeric composition so as to provide the desired configuration of thesingle or multi-layered device, once unfolded (e.g. following wetting bygastric content or by a medium resembling gastric content). The desiredconfiguration may be achieved by the incorporation of an enforcingpolymeric composition having a mechanical strength enabling, uponwetting and unfolding of the device, the preservation of the unfoldedconfiguration of the device, i.e. after ingestion. The enforcingpolymeric composition may be provided over the agent carrying layer(e.g. polymeric matrix), over the compartments comprising the agent,and/or may be integrally formed with or in the agent-carrying layer.

According to one embodiment, the enforcing polymeric composition is inthe form of one or more continuous or non-continuous polymer strips. Forexample, the strips may define a continuous or non-continuous frame atsaid device's periphery. The continuous or non-continuous frame may beeither affixed or attached to the matrix or integrally formed with thematrix. Further, when as a strip or in a continuous form to form theso-called frame, the enforcing strip/frame may comprise a single orplurality of defects, e.g. gaps, depressions or slits, typically alongthe width of the strip/frame. Without being bound by theory, it isbelieved that such slits are essential for providing breakable areasalong the strip/frame such that after a pre-determined time (e.g. whenexpulsion of the device from the body is desired, for example, after 12hours) the areas containing the slits weaken and break, resulting in thedisintegration of the device and its eventual removal from the stomachthrough the pylorus sphincter.

The combination of the enforcing composition, polymeric matrix and theagent or agent-releasing formulation constitute, at times, thefunctional layer (the functionality denoting that these combined layersconstitute a significant functional portion of the delivery device, onthe one hand, the gastro-retentivity, established by the enforcinglayer, and the active principle ingredient, i.e. the drug, diagnosticagent etc., on the other hand). According to this embodiment, theassembly step may comprise assembling at least one layer of theenforcing composition, e.g. in a form of one or more continuous ornon-continuous strips, with one or more layers comprising said agent oragent-releasing formulation or with the agent or agent-releasingformulation enclosed within the enforcing strips.

In accordance with one embodiment, the strips are in the form of a framehave inner boundaries defining a void, and the method comprisesassembling the frame with one or more layers comprising said agent oragent-releasing formulation, such that the one or more layers comprisingthe agent or agent-releasing formulation is affixed, attached orintegrally formed within said void. Alternatively or in addition, theagent or agent-releasing formulation may be enclosed, at leastpartially, within the frame.

The agent or agent releasing formulation may be contained in the devicein various forms. The incorporation of the agent or formulation thereofin the device is carried out in the assembly step. Thus, in accordancewith an embodiment of the invention, the assembly stem comprises atleast one of the following:

-   -   embedding said agent or agent releasing formulation into one or        more layers or into one or more compartments within one or more        layers (e.g. a single layer may comprise areas of different        composition of the polymer material forming it thereby forming        distinguishable areas/compartments within the layer and these        compartments may differently carry/release the agent so as to        provide a differential release profile of the agent from the        device);    -   trapping said agent or agent releasing formulation within at        least two layers (e.g. such that the layers form a pouch housing        the agent);    -   enveloping said agent or agent-releasing formulation within at        least one polymeric membrane segment;    -   attaching said agent or agent-releasing formulation to or in at        least one of said one or more layers of the device, or to a        carrier, the carrier may be in the form of nano- or        microspheres, nano- or microcapsules comprising particulate        matter (i.e. a matrix) accommodating the agent (by embedding,        entrapping or having the agent affixed to the particulate's        outer surface), beads coated or impregnated with the agent,        granules, pellets and compressed tablets.

In order to provide the desired mechanical strength in situ, once thedevice is in an unfolded state in the stomach, it is preferable that theenforcing polymeric composition or at least one other layer of thedevice comprises a polymer that is insoluble in gastric juices/content.Alternatively, the mechanical strength can be provided by a combinationof enteric and non-enteric insoluble polymers.

In addition to the aforementioned composition, the enforcingcomposition, irrespective of its shape or its number (e.g. number ofstrips made of the enforcing composition) within the device may furthercomprise a polymer, soluble in gastric content, which is eitherentrapped in the insoluble composition or is cross-linked in such waythat it does not exude from the insoluble composition and can not beextracted without disintegrating the whole frame.

In accordance with a preferred embodiment, the device is a laminateddevice comprising two external layers made of a first material andsandwiching one ore more layers comprising one or more strips made of asecond material and comprising the agent or agent releasing formulation.The external sheets may comprise one or more polymers selected from thegroup consisting, without being limited thereto, polymers soluble ingastric content, polymers insoluble in gastric content, and acombination of any two or more thereof.

Nonetheless, in accordance with some other embodiments, the laminateddevice comprises two external layers made of a first material andsandwiching one ore more layers comprising one or more strips made of asecond material, such that the one or both external layers comprise theagent or agent releasing formulation. In the context of this embodiment,the agent may be embedded in as well as deposited to the outer surfaceof one or both external layers, e.g. by inkjet printing. An ink-jettechnology that has been developed is such that allows the preparationof poly(lactic-co-polycolic acid) (PLGA) microspheres with uniformparticle size distribution [Radulescu D et al. Uniform paclitaxel-loadedbiodegradable microspheres manufactured by ink-jet technologyProceedings of the Winter Symposium and 11^(th) International Symposiumon Recent Advances in Drug Delivery Systems Salt Lake city, UT, USA(2003)]. These microspheres while carrying the agent may then be affixedor attached to the one or both external layers.

In accordance with one embodiment, the external layers comprise apolymer or polymer composition that is soluble in gastric content.

According to another embodiment, the external layer is comprised of amixture of a soluble polymer and an enteric polymer. According toanother embodiment, the external layer comprises a cross-linked watersoluble polymer, e.g. a soluble polymer cross-linked withglutaraldehyde, or an enzymatically hydrolyzed cross-linked gelatin anda derivative thereof.

Another example of external layer composition can be polyvinyl alcoholfilm, cross-linked with glutaraldehyde. Alternatively, said polyvinylalcohol film could be subjected to one or more freeze-thaw cycles toinduce crystallization.

Yet another example of external layer composition can be polyethyleneoxide film, cross-linked by gamma irradiation.

In addition to the mentioned composition, the layers independently maycomprise fillers, lubricants, plasticizers and other pharmaceuticallyacceptable processing adjuvants.

Irrespective of their composition, the one or more external layers maycomprise perforations. The perforations may be generated a priori, i.e.before the layers are integrated into the device; as a sub-step in theassembly step or following the assembly step (i.e. after all layers areassembled together into a whole unit), however, before the folding step;or the external layers may constitute a combination of materials suchthat when the device is wetted (or at least the external layers),perforations are produced. The dimensions, distribution pattern, shapeand amount of perforations may vary between one device to another,within a layer of a single device as well as between the two externallayers of a device, depending on the specific design of the deliverydevice and the manner of their formation (e.g. mechanical slicing ofholes or perforations resulting from dissolution of a component of theexternal layer following wetting by gastric content).

The assembly of the device's layers may be facilitated by variousintegration/lamination techniques known to those versed in the art. Theassembly may be achieved by applying onto at least portions of some ofthe layers an integration agent, prior to bringing the respective layersinto contact. The coating may be on one or more layers. A particularexample includes application to at least one surface of the externallayers, the strip/frame and the layer carrying the agent oragent-releasing formulation.

In accordance with one embodiment, the integration agent is an adheringagent which may be sprayed onto at least some of the layers of thedevice. In accordance with this embodiment, the adhering agent ispreferably an organic solvent, a mixture of organic solvents, or amixture of organic and water-based solvents such as salt solutions. Morepreferably the organic solvent is ethanol or mixture of ethyl acetateand ethanol.

In accordance with some other embodiments, the assembly is facilitatedby other techniques such as welding (heat-welding, welding by highfrequency, welding by ultrasound etc.), by curing (e.g. heat curing),fusion or any other technique involving melting both layers to formadherence at the interface between the layers as well as pressing thelayers together (with or without heating to temperatures aboveroom/ambient temperature). The said other techniques may involve the apriori application of an agent or substance to the layer so as tofacilitate the assembly, as appreciated by those versed in the art.

In another preferred embodiment, the composition of the outer layer istreated so as to modify the properties of the outer surface, e.g. so asto prevent adhering of the undulated surface of the device as a resultof folding. To this end, the assembly step may further comprise coatingof the outer surface of one or both external layers with ananti-adhering coating, e.g. powder coating, polymer coating, liquidspray coating, dispersion (latex) coating, etc. The application of thepowder may involve the a priori application of an adhering agent asdefined above so as to facilitate adherence of the powder coating ontothe respective layer.

In accordance with one preferred embodiment of the present invention,there is provided a method for producing a laminated device, preferablya gastro-retentive dosage form, comprising:

-   -   (i) assembling a laminated device that comprises:        -   a) a first external layer made of a first, typically            polymeric material;        -   b) a frame of a second, typically polymeric, material            mounted on the first external layer;        -   c) a drug-releasing formulation housed within the frame; and        -   d) a second external layer made of the first material and            mounted on the frame; and    -   (ii) folding the laminated device into a folded device; and    -   (iii) at least partially enclosing the folded device to produce        the delivery device, preferably gastro-retentive dosage form,        that can be administered orally.

In some preferred embodiments, the frame comprises one layer. In otherembodiments, the frame comprises two or more layers. In accordance withone, non-limiting, embodiment, the frame has a thickness of around 400microns, independent of the number of layers therein.

Further, in accordance with some other embodiments, the invention isdirected to a method for producing an oral agent-releasing dosage form,comprising:

-   -   (i) preparing or providing two first, essentially planar,        polymeric sheet portions made of a first polymeric material that        when wetted is permeable to the active agent, and a having outer        boundaries;    -   (ii) preparing or providing a second, essentially planar,        polymeric sheet portion made of a second polymeric material        defining a frame with outer boundaries and inner boundaries, the        outer boundaries being of essentially the same shape as the        outer boundaries of the first polymeric sheet portion and the        inner boundaries defining a void area;    -   (iii) preparing or providing a third, essentially planar,        polymeric sheet portion made of a third polymeric sheet        comprising an agent or agent releasing formulation releasable        from the third sheet when in contact with an aqueous medium and        defining a drug-containing and releasing matrix, said matrix        having outer boundaries to fit within the void area;    -   (iv) assembling the four portions such that said third sheet is        placed within the void area and the two (the second sheet        portion and the third sheet portion) being jointly sandwiched        between the two first polymeric sheet portions, with all the        outer boundaries essentially overlapping one another thus        yielding a laminated device;    -   (v) folding the laminated device into a form to fit into a        capsule, and inserting it within a capsule made of a material        that dissolves in the gastric fluids.

In some cases, this method comprises preparing first, second and thirdpolymeric sheets made of the first, second and third polymericmaterials, respectively, and cutting out the respective first, secondand third polymeric sheet portions therefrom such that all sheets haveessentially the same outer shape so as to facilitate the overlap betweenthe outer boundaries thereof.

Yet further, in accordance with another embodiment, a method forproducing an agent delivery device, comprising:

-   -   (i) assembling an agent or an agent-releasing formulation within        a generally planar assembly to form an integrated or laminated        device, wherein the generally planar assembly may comprise a        single or plurality of layers and may comprise or consist of a        frame;    -   (ii) manipulating the integrated or laminated device into a        compacted integrated device, wherein the projected surface area        of the compacted laminated dosage form is at least five times        less than that of the integrated device; and    -   (iii) at least partially enclosing the compacted device to        produce the gastro-retentive dosage form.

In accordance with this embodiment, the projected surface area of thecompacted device may also be at least six times, at least seven times,at least eight times, at least nine times and even at least ten timesless than that of the integrated/laminated device form. The agent/agentreleasing formulation may be assembled as part of a layer carrying thesame and surrounded, at least partially, by the frame. Further, thegenerally planar assembly may comprise one or more external layers. Apreferred embodiment in accordance with this method concerns a generallyplanar assembly comprising at least three integrated/laminated layers.

Further, in accordance with another embodiment of the present invention,the assembling step comprises introducing the agent or agent-releasingformulation into a layer of a second material (different from thematerial forming the external layers and/or the strips/frame).

As indicted above, the agent, which may be a pharmaceutical drug (orpro-drug) having a therapeutic or prophylactic effect or may be an agentuseful for imaging or another diagnostic utility as well as anutritional substance, is, in some cases, preferably provided betweenthe at least two layers of the matrix wherein the drug is in a formselected from, but not limited to, the group consisting of a polymericfilm, powder, solution, dispersion, or embedded in a semisolid, micro-or nano-spheres, micro- or nano-particles and a combination of any twoor more thereof.

In some preferred embodiments, the agent is a drug that has a narrowabsorption window in the gastrointestinal tract.

As appreciated by those versed in the art, the agent may be any lowmolecular weight compound, as well as an oligomer or polymer. In somepreferred embodiments, the agent is selected from therapeutic nucleicacid, a therapeutic nucleic acid sequence, therapeutic amino acid, atherapeutic amino acid sequence, the nucleic acids and amino acids maybe naturally occurring acids, chemically modified acids as well assemi-synthetic or synthetic acids, as known to those versed in the art.The agent may also be a peptidomimetic drug, an antibiotic agent,therapeutic ions (e.g. lithium, potassium), a vitamin, a bronchodilator,an anti-hypertensive agent, a diuretic agent, an anti-gout agent, ananti-hyperlipidemic agent, an angiotensin converting enzyme (ACE)inhibitor, angiotensin receptor blocker (ARB), an anti-parkinson agent,dopaminergic agent, a peripheral decarboxylase inhibitor, a COMTinhibitor and a combination of any two or more thereof.

In some embodiments, the drug is for local treatment of thegastrointestinal tract as is exemplified by, but not limited to,anti-tumor agent, a histamine blocker, a bismuth salt, a lipaseinhibitor, a synthetic prostaglandin, an anthelminitic agent, andanti-infective (such as antibiotic) agent, and a combination of any twoor more thereof.

Examples of the agent or drug families are exemplified by, but notlimited to L-DOPA, gabapentin, ropinirole hydrochloride, pramipexoledihydrochloride, bupropion, sumatriptan, phenylepherine, stavudine,didanosine (DDI), zidovudine (AZT), zalcitabine, ganciclovir, acyclovir,valganciclovir, zidovudine & lamivudine, lamivudine (3TC), abacavir,abacavir & zidovudine & lamivudine, valcyclovir, atazanovir, captopril,ramipril, fosinopril, Enalapril, quinapril, Losartan, Losartan/HCT,valsartan, valsartan/HCT, ciprofloxacin hydrochloride, rifaximin,cefdinir, cefaclor, cefditoren pivoxil, cefuroxime axetil, cefprozil,ceftibuten, loracarbef, gatifloxacin, moxifloxacin, levofloxacin,telithromycin, linezolid, doxycycline hyclate, moxifloxacin,levofloxacin, telithromycin, linezolid, rifaximin, voglibose, xenical,gastric lipase, pancreatic lipase and amylase, b12 intrinsic factor,voglibose, tacrine, omeprazole, rabeprazole sodium, rivastigmine,zolpidem, famotidine, rantidine, fexofenadine, metformin. baclofen.bisphosphonate. tacrolimus. rapamycin, cyclosporine. cetirizinedihydrochloride. piperacillin, miglustat, misoprostol, diclofenac &misoprostol and bosentan, mebendazole, alendronate, pamidoronate,zolendronic acid.

In some embodiments the drug is degraded in the colon.

Additionally, in accordance with another embodiment of the presentinvention, the folding step comprises: mounting the laminated devicebetween two opposite faces of a press, each of which constituting ablock having corrugated surface with ridges of one being essentiallyopposite to troughs of the other and essentially fitting one into theother; and pressing the two opposite faces one versus the other so as toform an undulated, three-dimensional device, wherein the undulationsthereof correspond to the shape of the corrugated surface.

In another preferred embodiment, the folding step further comprisesapplying a force so as to press the undulated device from two sides andin a direction perpendicular to the undulations, into a folded devicehaving folds formed along ridges and troughs of the undulations.

In some preferred embodiments, the folded device is folded parallel toone of the sides of the unfolded laminated/integrated device. In anotherpreferred embodiment, the folded device has folds of increasinglysmaller amplitudes upon extending away from the middle thereof so as tohave an overall rounded cross section and to allow the folded device tobe easily insertable into a container (envelop, e.g. capsule).

Thus, in accordance with the latter preferred embodiment, the twoopposing surfaces of the press have such corrugations that followingpressing, undulations with amplitudes that decrease from the middletowards the ends are formed, and upon the subsequent pressing in thesaid perpendicular direction an essentially circular cross-section iseventually attained, thus having an overall cylindrical form with alongitudinal axis parallel to the folds.

In one preferred embodiment, the eventual cross-section is such to allowthe insertion of the folded device into a capsule of a kindconventionally used in pharmaceutical dosage forms. In accordance withthis latter embodiment the process preferably further comprises at leastpartially enclosing the folded device within a capsule by pushing italong the longitudinal axis into one half of a capsule.

In accordance with a preferred embodiment of the present invention, theat least partially enclosing step of the above embodiment comprises:

placing the folded device into a capsule base (i.e. one half of thecapsule before enclosure); and

fitting a capsule cap (i.e. the other half of the capsule) onto thecapsule base so as to form an encapsulated folded integrated deliverydevice/dosage form.

In some other embodiments, the folded device is at least partiallyenclosed within an enclosure through at least one process selected from:wrapping (e.g. with a polymeric thread), dipping (e.g. to form mold),spraying (e.g. with a polymeric coating material), encapsulating,binding (e.g. with a polymeric thread), tying (e.g. with a polymericthread), molding (e.g. to form mold), enveloping and sealing, e.g.

The invention also provides an agent delivery device prepared inaccordance with any one or more of the alternative methods describedabove. In accordance with one preferred embodiment, the inventionprovides a dosage form comprising a folded laminated device enclosed ina capsule, for the controlled, gastroretentive release of an agent, thedosage form being prepared in accordance with any one or more of thealternative methods described above.

The present invention also provides a system for producing an agentdelivery device, the system comprising:

-   -   (i) an assembly apparatus adapted to assemble one or more layers        comprising one or more materials and an agent or an        agent-releasing formulation to form an intergraded device;    -   (ii) a folding apparatus adapted to fold the integrated device        into a folded integrated device;    -   (iii) an enclosing apparatus adapted to at least partially        enclose the folded integrated device within an envelop to form a        device in a form suitable for oral delivery.

In accordance with this aspect of the invention, the assemblingapparatus is preferably adapted to assemble an integrated device,preferably, a laminated device, the integrated device comprising:

-   -   (i) a first external layer comprising a first material;    -   (ii) one or more functional layers mounted on said first        external layer and comprising a second material and said agent        or agent releasing formulation;    -   (iii) a second external layer comprising said first material and        mounted on said functional layer.

Alternatively, the assembly apparatus may be adapted to assemble anintegrated, preferably laminated, device, the integrated devicecomprising:

-   -   (i) a first external layer of a first material;    -   (ii) a frame mounted on the first shielding layer;    -   (iii) a drug releasing formulation housed within the frame; and    -   (iv) a second layer of the first material layer mounted on the        frame;

In some preferred embodiments, the assembling apparatus furthercomprises a dicing system, adapted to cut at least one shaped piece froma sheet of the first material and at least one shaped piece from a sheetof the second material.

In accordance with one embodiment, the dicing system is adapted to cutat least two shaped pieces from a sheet of a first material and at leastone shaped piece from a sheet of a second material. The shape of the twopieces from the first material and the shape of the piece from thesecond material may be the same or different.

According to one embodiment, the at least three pieces (two of the firstmaterial and one of the second material) are similarly cut such thattheir outer boundaries overlap in the assembled device.

In accordance with another embodiment, the pieces may be differentlycut. In some cases the two pieces of the first material preferably haveserrated perimeters, at least throughout a portion of the perimeter ofthe piece, in the shape of a plurality of teeth (or other form ofprotrusions, such as notches or grooves) such that upon assembly, atooth at the perimeter of one piece overlap with a groove at theperimeter of the other piece of first material. In one other embodiment,the integrated device comprises at least three layers, two serratedexternal layers made of a first material and sandwiching anagent-comprising layer, whereby from an exploded side view of theintegrated device the teeth/notches at the perimeter of the two externallayers at least partially intersect (i.e. overlap). In accordance withsome other embodiments, teeth/notches at the perimeter of the twoexternal layers do not intersect (i.e. from an exploded side view of thedevice the protrusions formed by the teeth of the two layers alternate).

In some embodiments, assembly apparatus is also adapted to assemble theagent or agent releasing formulation when the agent or agent releasingformulation is either:

-   -   embedded into one or more layers;    -   trapped within at least two layers;    -   enveloped within at least one polymeric membrane segment; or    -   attached to or in any one of at least one layer of the device,        nano- or microparticles, powder, liquid or compressed solids or        to or in a matrix;

and any combination of the above.

In some case, the assembling apparatus further comprises an applicationapparatus adapted to apply an integration agent onto at least one layerprior to the assembly. The application apparatus may comprise a sprayingmechanism for spraying said integration agent onto at least one of thedevices layers. The integration agent may be any agent suitable forfacilitating adherence, welding, fusion, curing etc., between two ormore of the devices layers.

In accordance with one embodiment, the integration is facilitated byspraying an adhering agent (e.g. an organic solvent such as ethanol ormixture of ethyl acetate and ethanol, or a mixture of organic andwater-based solvents such as salt solutions).

In accordance with an alternative embodiment, the integration isfacilitated by welding (e.g. heat-welding, welding by high frequency,welding by ultrasound etc.).

The system may further comprise a perforation apparatus adapted toprovide at least one of said external layers with perforation. This maybe achieved by the use of an to array of pins or slicing knives pressesagainst the layer to be perforated. As indicated above, the perforationsmay be of various dimensions and distribution patterns, and may bedifferent between the two external layers. To this end, the perforationapparatus may comprise a series of differently arranged array of pins,the pins (or knives) being of the same or different dimensions etc.

The assembling apparatus may also comprise an assembly jig (holdingboard), adapted to assemble two external layers, a frame, an agent oragent-releasing formulation into a predetermined form; and a pressingassembly adapted to press the predetermined form into the integrateddosage form.

The system preferably further comprises a coating apparatus for forminga coating or powder layer on at least one side of the integrated device.The coating apparatus may be a powdering apparatus for forming a powderlayer on at least one side of the integrated dosage form.

In accordance with an embodiment of the invention, the folding apparatuscomprises a press with two opposite faces, each of which having acorrugated surface with ridges of one being essentially opposite totroughs of the other and essentially fitting one into the other; wherebyupon placing the laminated device in the press and pressing the twoopposite faces one versus the other, an undulated, three-dimensionaldevice is formed with undulations that correspond to the shape of thecorrugated surface. The two faces are at times referred to as an upperbend tool and bending base.

In accordance with some other embodiments the folding apparatuscomprises:

-   -   (i) a mounting jig/bending base having a corrugated surface for        mounting the integrated dosage form thereupon; and    -   (ii) a pressing block/upper bending tool having corresponding        ridges to said corrugated surface for pressing on the integrated        dosage form so as to form an undulating three-dimensional        integrated dosage form, wherein the undulations thereof        correspond to the shape of the corrugated surface.

In another preferred embodiment, the folding step further applying aforce so as to press the undulated device from two sides and in adirection perpendicular to the undulations, into a folded device havingfolds formed along ridges and troughs of the undulations.

In a preferred embodiment, the system of the invention comprises:

-   -   (i) an assembling apparatus for assembling an agent within a        generally planar laminated assembly to form a laminated device;    -   (ii) a manipulating apparatus adapted to manipulate the        laminated device into a compacted laminated device, wherein the        projected surface area of the compacted laminated device is at        least five times less than that of the laminated device; and    -   (iii) an enclosing apparatus for at least partially enclosing        the compacted laminated device to produce the agent delivery        device.

The system of the invention also comprises an enclosing apparatus. Inaccordance with a preferred embodiment of the invention, the enclosingapparatus comprises an encapsulating apparatus. In accordance with oneembodiment, the encapsulating apparatus comprises a capsule jig forholding a capsule base and the same or different capsule jig for holdinga capsule cap, whereby upon insertion of the folded integrated deviceinto said capsule base, said capsule cap is fitted onto said capsulebase comprising the folded integrated device. The capsule jig may alsocomprise a revolver for revolving the capsule jig during operation.

The present invention also provides a folding apparatus for folding asingle or multi-layered sheet, the folding apparatus comprises a presswith two opposite faces, each face having a corrugated surface withridges of one corrugated surface being essentially opposite to troughsof the other corrugated surface and essentially fitting one into theother; whereby upon placing at least a portion of the single ormulti-layered sheet in the press and pressing the two opposite faces oneversus the other a three dimensional device having at least said portionundulated is formed with undulations that correspond in shape to that ofsaid corrugated surfaces.

The folding apparatus in accordance with this aspect of the invention ispreferably designed such that the corrugated surface is formed by aseries of fingers (e.g. in the form of parallel blocks) extendingdownwardly and comprising a movable central finger having a firstlength, and at least one pair of secondary movable fingers siding saidcentral finger and having a second length being shorter than the firstlength, the folding apparatus further comprising a control utility forcontrolling upwardly and to downwardly sequential movement of saidcentral finger and at least one pair of secondary fingers towards thesaid other corrugated surface. The fingers may have a widthcorresponding to one dimension of the sheet to be folded (preferably thesame or wider).

In accordance with another embodiment, the folding apparatus comprises amovable central finger having a first length, at least one pair ofsecondary movable fingers siding said central finger and having a secondlength being shorter than the first length, and a third pair of movablefingers having a third length being shorter than the second length, eachfinger in the third pair siding one of the secondary pair of fingers.

The folding apparatus in accordance with this embodiment may also beequipped with a secondary press having opposite faces perpendicular tothe faces of said primary press and adapted to press the undulateddevice so as to form a folded device having a dimension which is atleast five times smaller than that of the sheet prior to pressing.

In accordance with this aspect of the invention, there is also provideda method for folding a single or multi-layered sheet comprising:

-   -   (i) placing said sheet in a folding apparatus; and    -   (ii) pressing the two opposite faces of the first press one        versus the other to form an undulated, three dimensional device        with undulations that correspond in shape to that of said        corrugated surfaces.

The method may also comprise activating the secondary press so as topress the undulated device in a direction perpendicular to the directionof pressing by said first press so as to obtain a folded device having adimension which is at least five and even at least as up to ten timessmaller than that of the sheet prior to pressing.

The scope of this invention should not be construed as being limited tothe aforementioned embodiments. It should be understood that anycombination or permutation of these exemplary embodiments is within thescope of this invention.

Turning now to FIG. 1A, a simplified flowchart 100 is presented,illustrating the major process steps of a method for producing acompacted gastro-retentive dosage form 131 in accordance with apreferred embodiment of the present invention.

In an assembling step 105, at least one section of a first material 103,a second material 106 and another section, preferably of the firstmaterial 107 are each diced into at least one predetermined shape andare oriented such that material 107 is used to form a base.

Typically, the active agent 101 is first at least partially physicallyretained within or on the at least one section of material 103. In otherembodiments, the agent is dispensed into the material 103. The at leastpartial retention of the agent may be achieved by any means known in theart, including embedding, adsorbing, enclosing etc, as well as others,such as those disclosed in U.S. Pat. No. 6,685,962, whose disclosure isincorporated herein by reference.

In accordance with one embodiment, the agent 101 is assembled optionallytogether with at least one material 103 inside a frame of secondmaterial 106 to form a laminated device 111, which, structurally, isgenerally planar. Optionally, another layer of the first material 107may be mounted on top of the frame. The apparatus used to perform thisstep may be identical, similar or different to the apparatus of FIG. 5described hereinbelow.

Thereafter, in a manipulating step 115, the laminated device 111 ismanipulated into a compacted device 121. The manipulating step maycomprise one or more of folding, bending, twisting, wrapping, winding,rolling, crimping or any other mechanism known in the art to reduce theprojected surface to volume ratio of the generally planar assembly ofform 111 by at least a factor of two, more preferably by at least oneorder of magnitude and yet more preferably by at least two orders ofmagnitude. The apparatus used to perform this step may be identical,similar or different to the system of FIGS. 7A, 8 and 9 hereinbelow.

Laminated device 111 typically has a projected surface to volume ratioof 1.25 mm⁻¹ whereas after the manipulating step 115.

The compacted laminated device 121 is at least partially enclosed in anenclosure 123 in enclosing step 125 to form a folded agent deliverydevice for oral intake 131. The enclosure may be of the form of a unitenclosure or may be a liquid polymer or gel as well as other enclosuresas described hereinabove. The enclosure itself may be a continuous layeror may be discontinuous. In a preferred embodiment, the enclosure is acapsule comprising two parts, a capsule base and a capsule cap. In step125, the compacted form 121 is placed in the capsule base and thereafterthe capsule cap is fitted over the base to fully enclose the compactedform.

Notwithstanding the above, enclosing step 125 may comprise one or moreof the following processes: wrapping, dipping, spraying, encapsulating,binding, tying, molding, enveloping, inserting and sealing or any otherprocess known in the art, so as to obtained a compacted device. It hasbeen found by the inventors that following oral intake and upon releasefrom the enclosure and unfolding, the unfolded device isgastro-retentive. The resultant unfolded device may typically beretained in the stomach for 3-12 hours. During this time, the agent isreleased from the device, preferably in a controlled manner.

Reference is now made to FIG. 1B, which is a simplified flowchart 105illustrating a method for producing an encapsulated folded agentdelivery device 198 in accordance with a preferred embodiment of thepresent invention.

In a dicing step 110, a first material sheet 104, such as a polymericmaterial, is diced into at least two essentially planar sheet portions112, 113. A second material sheet 108, which may also be a polymericmaterial (the same or different as the first material) is diced into oneor more essentially planar sheet portions 116. A third material sheet109, which may also be a polymeric material, comprising an active agent102 is diced into at least one essentially planar sheet portion 118 of apredetermined shape.

In some alternative embodiments, sheets 109 are pre-diced and the activeagent 102 is inserted therein, prior to dicing step 110. Sheets 109 arenot diced in step 110 in cases where the cost of the active agent isvery high and the agent cannot be wasted in this step.

The apparatus used to perform this step may be identical, similar ordifferent to the apparatus of FIG. 5 described hereinbelow.

In a preferred embodiment of the present invention, the dicing stepcomprises several sub-steps as shown in further detail in FIG. 2.

In a spraying step 120, portions 112, 113, 116 and 118 are sprayed witha spray 124. The spray is typically liquid and preferably an organicliquid. Most preferably, the spray comprises ethanol. Alternatively, thespray comprises a solid adhesive powder or a liquid adhesive. Thespraying process is adapted to enhance the adhesive properties of thesurfaces of portions 112, 113, 116 and 118. Preferably spraying step 120renders the sheet portions sticky.

In some embodiments, sheet 118 is not sprayed, but rather placed withinsheets 112, 113 and 116.

In some other embodiments, the spraying step is an integral part ofassembling step 130. Diced sheet portions 112, 113, 116 and 118 may besprayed in a specific sequence, coordinated with the assembling step.For example, portion 112 may first be sprayed and then one or moreportion 116. Portion 116 may then be assembled on sheet portion 112.Thereafter, sheet portion 118 may be sprayed and mounted within 116 on112. Thereafter portion 113 may be sprayed and mounted on portions 116and 118 to form an upper layer. Many different variations of these steps(110, 120 and 130) are envisaged within the scope of the invention.

Sticky first sheet portions 122, 123 (at times referred to herein by theterms “external layers”), sticky one or more essentially planar secondsheet portions 124 (at times referred to herein by the term “frame”) andsticky third sheet portion 126 (at times referred to herein by the term“matrix”) are then assembled together in an assembling step 130.Typically, sticky one or more essentially planar second sheet portions124 are first assembled to form a frame on one sticky first sheetportion 122. Thereafter, sticky third sheet portion 126 comprising theactive agent is placed within the second sheet portions 124. Thereafterthe second portion of sticky first sheet 123 is placed on the secondsheet portions 124 to form a multi-layer assembly 132. In someembodiments, assembly may be facilitated by applying onto some of thelayers following their orientation and placement in the assembled unitsome pressure, such as a pressure of 0.8 to 1.5 gr/mm² to form theassembled laminated device 132.

In some embodiments of the invention, an active agent 134 is placedwithin the frame at step 130, at times, instead of being introduced intolayer 109 prior to the dicing step.

Thereafter, in an optional (albeit preferable) first quality controlstep 150, the laminated device 132 is visually inspected to check thequality of the adhesion between the parts. Furthermore the dimensions ofthe resultant laminated device 132 are measured and checked to see thatthey meet with a required specification. If there is any significantnon-conformity, the laminated device 132 is rejected in reject stream156. If the device meets all the requirements the accepted device 152 ispassed to a powdering step 160.

In powdering step 160, the laminated device 152, is coated with asuitable coating, e.g. an anti-adhering powder, to form a powderedlaminated device 162. The powder is selected from a pharmaceuticallyacceptable cellulose or derivative thereof, silicate or talc.

In accordance with one preferred embodiment, the powder ismicrocrystalline cellulose (Avicel, obtained from FMC BioPolymers).

The powdering process may be performed in accordance with the stepsillustrated in FIG. 3 and the apparatus used to this end, may beidentical, similar or different to the system of FIG. 6A-6B hereinbelow.

In alternative embodiments, the powdering step is replaced with acoating step, in which the laminated device is coated with a liquid orother material.

In a second optional (albeit preferable) quality control step 170, thepowdered laminated device 162 is visually inspected to check the qualityof the powdered surface thereof. If the device 162 does not meet therequired quality, it is rejected in stream 176. If it meets the requiredquality, an “accepted” powdered laminated device 172 is passed to afolding step 180.

In folding (bending) step 180, device 172, which is essentially planar,is placed in a folding apparatus, such as, but not limited to, theapparatuses of FIGS. 7 to 9.

In accordance with one preferred embodiment, laminated device 172 hasdimensions of height/width/thickness 45×(18 to 24)×0.7 mm. Uponcompleting the folding process 180, the resulting folded device 182 hasdimensions 7.3×(18 to 24)×7.7 mm. In accordance with this embodiment,the projected surface:volume ratio of the laminated device 172 are 1.25mm⁻¹, whereas after folding, the projected surface to volume ratio are0.0161 mm⁻¹.

In folding step 180, laminated device 172 is preferably folded into anaccordion-to like shape. This folding step 180 normally comprisesinserting the device into a press having two corrugated faces.Specifically, the laminated device 172 which is substantiallytwo-dimensional is mounted onto a bending base having a corrugatedsurface; and pressed by a block having ridges corresponding to saidcorrugated surface so as to form a folded device 182 having anundulating three-dimensional surface, wherein the undulations thereofcorrespond to the shape of the corrugated surface.

Additionally or alternatively, laminated device 172 may be manipulatedto further reduce its projected surface area by e.g. folding, bending,twisting, wrapping, winding, rolling or crimping in the same or anotherdimension of the undulated three dimensional device 182.

In accordance with one embodiment, the folding step 180 may comprise anumber of manipulations on the unfolded laminated device 172. Forexample, the folded device following pressing in the folding apparatusmay be further squeezed by applying a force perpendicular to a thirddimension of the undulating three-dimensional device to the two endsthereof so as to reduce the projected surface area of the resultantfolded device 182. This additional squeezing is at times an integralpart of the encapsulation step 190 so as to facilitate the insertion ofthe folded device into the enclosure (e.g. a capsule).

In encapsulated step 190, folded device 182 is then encapsulated insidea capsule 184. Step 190 may, for example, comprise placing (typically bysqueezing) the folded device into a capsule base and then fitting acapsule cap onto the capsule base so as to form a encapsulated foldeddelivery system 192. As appreciated by those versed in the art, otherencapsulation process may be applied instead of the above encapsulationstep 190.

In accordance with one preferred embodiment, capsule 184 is made ofgelatin, however, any alternative pharmaceutically acceptable materialsknown in the art may be used. The capsule may be of any suitablegeometry to house folded device 182. In accordance with one embodimentof the invention, the dimensions of capsule 184 are: internal: diameterof 7.8 mm, length 23-25 mm; external diameter 8.15 mm, length 23.3-25.3mm. Capsules may be obtained commercially from Capsugel, (NJ, USA). Itis noted that the above dimensions are provided for illustration onlyand should not be construed as limiting the invention. Any other type ofcapsule and any other dimensions are as well applicable. Preferably, thecapsule (or any other enclosure) is selected so as to facilitate oralintake of the folded delivery system.

In some embodiments, encapsulation step 190 is replaced with anenclosing step in which the device 182 is enclosed by some othersuitable enclosure means known in the art.

In a third optional quality control step 195, encapsulated foldeddelivery device 192 is visually inspected for faults. If any significantfault or defect is found, device 192 is rejected into a reject stream196. If device 192 passes the quality control inspection and isconsidered as approved device 198, it is passed to a packaging step 197.

Typically in packaging step 197, a number of encapsulated deliverydevices 198 are packed together in a suitable packaging 194 to provide apackage 199 of deliver devices. Preferably, the encapsulated deliverydevices 198 are packed in blister packages as are known in the art. Anon-limiting example of a blister package is that commercially availablefrom O. M. A. R. (Italy). It is noted that the packaging may beperformed automatically, by the use of automated machines such asFantasy Plus or others as known in the art.

The packaged delivery device may then be further labelled appropriatelyand packed into boxes or cartons, ready for marketing and/or storageand/or shipping.

In other preferred embodiments, the delivery device 198 are not packedinto blisters but rather into packed into bottles, jars, packets, boxesor other dispensing means known in the art.

The resultant packages 199 are then ready for use including storage,transportation and marketing.

Reference is now made to FIG. 2, which is a simplified flowchart 200illustrating further details of dicing step 110 step of FIG. 1A.

In a first step, referred to as the removing borders step 210, a sheetof material 202, is cut and its borders 206 are removed so as to form atleast one essentially rectangular or oval planar large segment 212 ofthe sheet. It is noted that this step is optional and is typicallyrequired in cases where the large sheet has defects (e.g. bents or otherirregularities) in their perimeter.

In a cutting step 220, the large segment 212 is cut into several piecesof at least one shape 222, such as a square, rectangle, trapezoid, oval,circle as well as other polygonal shape (which may be skewed ortruncated at one or more of their corners). In accordance with onepreferred embodiment, the shape of the sheets is a rectangle truncatedat its four corners (at times with curved sides). Remnants materials 226are removed from the shapes 222, 224 and 228. In some embodiments thesheets 222, 224 and 228 are cut into quarters at this stage. Steps 210,220 may be performed on several different materials in series or inparallel or in a combination thereof. For example, sheet 202 mayrepresent a first, typically polymeric, material that when wetted ispermeable to the active agent and is cut into shape 222, sheet 204 mayrepresent second typically polymeric, material that has a mechanicalstrength such that when the device is wetted and unfolding, the secondpolymeric material facilitates retention of the unfolded device in anessentially planar configuration, and is cut into shape 224, and sheet208 may represent a third, typically polymeric material, or may benon-polymeric and is cut into shape 228. The sheet 208 is adapted tocontain or house one ore more active agents. In some cases the agent isembedded in sheet 208. In other cases, the agent may be retained/boundeither physically or chemically to the sheet 208. In yet otherembodiments, the agent may be entrapped between at least two layers ofthe sheet. The above characteristics of the sheets 202, 204 and 208 maybe achieved by the selection of one or a combination of polymers whichare soluble or insoluble in gastric content as detailed hereinabove. Itis noted that while preferably sheets 202, 204 and 208 have differentproperties upon wetting, i.e. to provide a delivery device with severallayers originating from different sheets; it is also possible that alllayers of the resulting device be derived from the same sheet.

In one preferred embodiment, once all the required shaped pieces 222,224 and 228 have been cut in step 220, they are oriented either manuallyor automatically or in combination thereof in an orientation step 230.This orientation step may involve two-dimensional and orthree-dimensional orientation on a reference surface, such as a cuttingboard. Oriented pieces 232, 234 and 238 are then mounted into a dicingapparatus forming part of assembling step 240. Assembled mounted pieces242, 244 and 248 are then diced to shape in dicing step 250. The dicingstep may dice pieces 242, 244 and 248 in series or in parallel, in oneor more orientation, using one or more dicing blades. The diced shapedpieces 252, 254 and 258 are then transferred to either a spraying stepsuch as in step 120 or directly to an assembling step, such asassembling step 130 in FIG. 1B. Alternatively, the spraying step and theassembling step may be integrated as described with respect to FIG. 1B.

In one embodiment, the shaped pieces 242, 244 and 248 are diced inparallel such that a first and second sheet pieces 242 have, at least inpart, similar dimensions with similar outer boundaries (so as to formthe layers which are referred to herein, at times, by the term “externallayers”); the second sheet pieces form 244 is in the shape of frame(s),suitable for mounting on one of the first sheet pieces and for housingthe third sheet piece therein (piece 248, typically, the agent-carryinglayer). In an alternative embodiment, a first and second sheet pieces242 have at least in part, similar dimensions however, with a differentoutline of the outer boundaries.

Reference is now made to FIG. 3, which is a simplified flowchart, 300illustrating further details of a powdering 160 step of FIG. 1B.

In an orientation step 310, one or more laminated devices 302 areorientated to lie horizontally. The devices 302 may be similar to,identical to or different from device 152 of FIG. 1B. According to oneembodiment, the different laminated devices 302 may be oriented as shownin sliding board 611 shown in FIG. 6B.

In a preferred embodiment, laminated device 302 comprises a lowerexternal layer of first sheet, upon which a perimeter frame of secondsheet from a second material is mounted. Inside the frame are one ormore pieces of the third sheet containing at least one active agent.Mounted on the frame, so as to cover the one or more pieces of the thirdsheet is another piece of the first sheet, as further illustrated inFIG. 4 hereinbelow.

In a first spraying step 320, the orientated devices 312 are sprayed onone face of the laminated device 312 (e.g. the upper face of thelaminated device) with ethanol 324 (according to one embodiment, with 2mg per spray pulse) or any other suitable organic solvent to provide asticky upper-faced device 322.

Thereafter, in a first powdering step 330, form 322 is powdered withpowder 334 so as to form a non-sticky upper-faced device 332. Powder 334is typically an anti-adhering powder such as that described inconnection with step 160 in FIG. 1B. In to accordance with oneembodiment, a layer of 0.05 mm thickness or 0.03-0.07 g/laminated dosageform of powder is sprayed on device 322 to form the non-stickyupper-faced device 332.

In an inverting step 340, device 332 is inverted about a horizontalaxis, such that the non-sticky face is now face-down. It is noted thatthe inverting step may be performed by an automated machine, e.g. arobot, or manually.

In a second spraying step 350, a face-down device 342 is sprayed withethanol 354 to form a sticky lower faced device 352. This step issubstantially similar to step 320.

In a second powdering step 360 the sticky lower faced device 352, ispowdered with an anti-adhering powder 364 (which is typically the sameanti-adhering powder applied to the upper face 332) to form a two-sidedanti adhering device 362. Device 362 may be similar or identical to thedosage forms disclosed in FIGS. 1-3 of U.S. Pat. No. 6,685,962 toFriedman et al. incorporated herein by reference in its entirety.

It should be understood that though the flowcharts herein may refer toone delivery devices, they are not limited thereto. The methods andapparatuses of the present invention are designed to produce a largenumber of delivery devices and are preferably designed to mass producesuch delivery devices.

Reference is now made to FIG. 4, which is a schematic illustration ofthe main steps of the method of FIG. 1B.

In a first assembling step, 410, parallel to step 130 of FIG. 1B, sheetshapes 422, 423, 424 and 426 (corresponding to portions 122, 123, 124and 126 in FIG. 1B) are assembled. Typically, shape 424 is assembled onshape 422 and thereafter, shape 426 containing the active agent isinserted into shape 424 thereby placed on shape 422. Thus, shapes 424and 426 form a second layer on first layer 422. Shape 424 is sometimesreferred to as a frame and the combination of the frame with the agentcarrying layer 426 is sometimes referred to as the functional layer. Insome embodiments, a third layer is formed by assembling shape 423 on thesecond layer so as to form a laminated device 432. Many possiblevariations of step 410 are envisaged, and the invention should not benarrowly construed as limited to the embodiments disclosed in thespecification and figures.

In a folding step 420, the multi-layer laminated device 432 is firsttypically pressed in a press machine such as, but not limited to thatillustrated in the folding apparatus 700 of FIG. 7, comprising upperbend tool 900 of FIG. 8 and bending base 1102 of FIG. 9.

An essentially planar laminated device 432 is placed on a bending base442 below an upper bend tool 444. The upper bend tool 444 is thenpressed down onto laminated device 432 and forces the laminated deviceinto a folded or bent device 446, similar or identical to device 182 ofFIG. 1B.

In a second part of folding step 420, folded device 446 is pressed fromthe sides to squeeze the folds together to form a compacted foldedlaminated device 482, similar, dissimilar or identical to device 182 ofFIG. 1B. In some cases, device 446 is pushed about a third axis so as toform the folded laminated device 482 in dimensions suitable forinsertion into an enclosure.

The folded device 482 is then enclosed in an enclosing step 430, whichmay be similar, dissimilar or identical to encapsulation step 190 ofFIG. 1B. In accordance with this particular embodiment, folded device482 is inserted into a capsule 484 by first pushing the compacted foldeddevice 482 into a capsule base 486 and fitting onto the capsule base thecapsule cap 488 (the second half of the capsule) to form encapsulateddevice 492. It should be understood that many variations for enclosingdevice 484 are envisaged for this enclosing step and the inventionshould not be narrowly construed as limited to the embodiments disclosedin the specification and figures.

In a packaging step 440, encapsulated devices 492 are packaged insuitable packaging 494, similar, dissimilar or identical to packaging194 of FIG. 1B and the resultant packaged devices are ready for furtherprocessing including storage, sale or further packaging. In accordancewith one embodiment, packaging may be obtained by any technique knownfor the preparation of blister packages (not shown). Imprinted cutblister packages may then be inspected in an optional quality controlstep (not shown) and any rejected packages may be discarded whileaccepted blister packages may be then packed in boxes for storage,shipping or selling etc. (not shown)

Turning now to FIG. 5, a simplified perspective view of an apparatus 500for dicing and assembling a laminated device can be seen, in accordancewith a preferred embodiment of the present invention.

As can be seen in FIG. 5, apparatus 500, comprises an assembly plate501, a cutting tool 502, a piston 503, a cutting board 504, an X slider506, a Y slider 507 at least one support 512. The apparatus ispreferably at least in part automatically controlled and is operative tomove sliced pieces from the sheet of material onto the assembly plate501 by means of sliders 506 and 507. Once actuated, cutting tool 502 isoperative to cut the sheet of material on board 504 into the slicedpieces, the pieces being of a predetermined shape so as to form pieces112, 113, 116 and 118 as in FIG. 1B. Once on the assembly plate 501 eachsliced piece is sprayed by a spray nozzle 510. In accordance with oneembodiment, a layer of a plurality of sliced pieces are placed onassembly plate 501 and simultaneously sprayed with an adhering substanceas described above. Thereafter, a second layer of a plurality of pieces,typically of a second material, are mounted on the first layer of slicedpieces and sprayed. In accordance with one embodiment, this layer of asecond material forms the frame into which the pieces carrying the agentare individually inserted to form a second layer which is also sprayed.This sprayed second layer is covered by a third layer. The constructionof the layers is also illustrated hereinbelow with respect to FIG. 4.

FIG. 6A is simplified perspective view of an apparatus 600 for powderingand spraying a laminated device such as 152 in FIG. 1B, in accordancewith a preferred embodiment of the present invention. Apparatus 600comprises a base plate 610, carrying a slide board 611 upon which thedevices 312 or 432 may be placed. The sliding board is movable along aslide lead screw 620 for so as to locate the sliding board with thedevices thereon in position for spraying and powdering. The devices maybe sprayed on one or more sides with an agent such as ethanol by meansof a spraying system 612 so as to form sprayed devices 322. Thereafter,the devices 322, may be coated or powered by coating dispersion system613 so as to produce coated devices 162, 332. The coated devices maythen be inverted (manually or automatically) and the spraying andcoating procedure may be repeated to form powdered devices 162 and 362.Apparatus 600 comprises a powder cartridge 614 a vibrating system 615for facilitating powdering of the sprayed devices 322 and 352 by thevibration of cartridge 614.

In one embodiment, the laminated devices 432 are moved mechanically bysystem 600 onto the base plate 611, is sprayed with ethanol by system612 on one side thereof and is moved back by system 600 to the its pointof origin. Thereafter, the vibrating system 615 is activated and coatsthe device with a powder, for example. The device is then moved bysystem 600 in the direction of the dispersion system 613 and the coatedsprayed device is moved mechanically to it point of origin in system600.

FIG. 6B is a perspective view of slide board 611 showing a plurality oforiented laminated devices 630 arranged thereon for handling inapparatus 600.

Reference is now made to FIG. 7A, which is a simplified perspective viewof an apparatus 700 for folding a laminated device, in accordance with apreferred embodiment of the present invention. Folding apparatus 700comprises a folding press 740 comprising two faces, an upper bend tool708 and a bending base 710, each having a corrugated surface; thefolding apparatus also comprises a number of pistons 701 (for movingdownwardly and upwardly upper bend tool 708), 702 (for moving foldeddevice 446 away from bending base 710 by pushing push block 706), 703(for further squeezing folded device 446 to obtain device 482 in FIG.4), and 704 (for pushing folded device 482 into the capsule base 486); apush block 706, a side slide block 707, an upper bend tool 708, andbending base 710, and a number of fingers 711, 712 and 714. Furthershown in FIG. 7A is the encapsulating apparatus 750 which is discussedin more detail in FIG. 7B.

Firstly, a laminated device 432 is placed onto bending base 710 andupper bend tool 708 is automatically lowered towards bending base 710carrying the laminated device 432 thereby applying pressure onto thedevice so as to form folded device 446. Thereafter, push block 706pushes and thereby releases the folded device such as 446 (FIG. 4), fromthe bending base 710. Thereafter, side slide block 707 presses thedevice 446 into a pressed device, such as 482 in FIG. 4. Subsequently, amechanical bar 720 pushes device 482 into a capsule base 486 so as toform an encapsulated dosage form 492 (FIG. 4).

In FIG. 7B, further details of an encapsulating apparatus 750 generallyshown in FIG. 7A are illustrated. Specifically shown are a piston 704,an encapsulation pin 720, a squeezing hole 724, a capsule base holder730 on a capsule base revolver 726 carrying a plurality of capsule baseholder 730 and a rotation axis 778. In operation, a folded device 482 ispushed by side slide block 707 in between encapsulation pin 720 and asqueezing hole 724. Piston 704 then activates encapsulation pin 720 topush the folded device through squeezing hole 724 and thereafter into acapsule base located in the capsule base holder 730. Once introducedinto a capsule base, rotation axis 778 rotates the capsule base revolver726 so as to position the following capsule base holder in position forencapsulating the next folded device. The capsule cap may then be fittedonto the capsule base manually or automatically (not shown).

FIG. 8 shows further details of an upper bend tool such as 708 of FIG.7A. In this specific, non-limiting example, an upper bend tool 800 isshown comprising a plurality of bending fingers, including, a centerfinger 802, a pair of second fingers 804, and a pair of outer fingers806 and connection pin 808. The plurality of fingers provide the upperbend tool with a corrugated surface. Each finger is independentlymovable downwardly by the actuation of connecting pin 808. As shown inthis specific embodiment, the corrugated surface is formed a centralfinger 802 having a first length, and a pair of secondary movablefingers 804 siding said central finger 802 and having a second lengthbeing shorter than the first length, and a third pair of fingers 806having a third length that is shorter than the second length. Thecorrugated surface is provided by a proximal ends 820 of each fingerbeing vertexed. It is to be noted that other shapes of proximal ends 820are applicable, such as curved and concaved ends, zigzagged ends, andcombinations of same.

FIG. 9 shows a side view of the arrangement of components in a foldingpress 900 (740 in FIG. 7A) including a bending base tool 910 having anundulating/corrugated surface; a plurality of fingers forming part of anupper bend push 912 and including a central finger 914, a pair ofsecondary fingers 916, a pair of intermediate fingers 918 and a pair ofouter fingers 920. Further shown is undulated/folded device 922. Inoperation, center finger 914 is forced down onto a device 432, andthereafter in sequence, two secondary fingers 916, two intermediatefingers 918 and two outer fingers 920 thereby forcing device 432 toobtain the shape of the corrugated surface as represented by device 922.The device 922 is then pushed by push block 706 (FIG. 7A) intoencapsulating apparatus 750. It is noted that other embodiments of thepress apparatus are applicable, such as a press in which other sequencesof movement (downwardly and upwardly) of the fingers takes place. Forexample, the fingers may be activated such that together with thecentral finger the two siding fingers (secondary fingers) are lowered,followed by the intermediate etc., or all fingers may be presseddownwardly together. Further alternatively, the pressing device may beconstructed such the array of movable fingers are located so as to formthe base onto which the integrated device is placed and upon operation,press is achieved by moving the finger(s) upwardly towards a respectiveupper bend tool.

FIG. 10 shows a perspective view of a push block 1000 corresponding topush block 706 of FIG. 7A. Typically, the push block 1000 has acorrugated surface 1002 which matches the corrugated surface of thebending base 710 of FIG. 7A.

Reference is now made to FIG. 11A-11E, which shows a perspective sideview of an essentially planar delivery device 1100 and the differentcomponents of the device 1102, 1104, 1106, and 1108, in accordance withanother preferred embodiment of the invention. According to thisspecific embodiment, the device 1100 is constructed from two externallayers 1102 and 1108 having a plurality of perforations 1110 andsandwiching a frame 1106 hosing an internal matrix 1104 carrying theagent. While layers 1102 and 1108 may be formed of the same or ofdifferent materials and may have the same or different thickness, it ispreferable that layers 1102 and 1108 are formed of the same polymericmaterial and have substantially similar thicknesses. Most preferablylayers 1102 and 1108 are made of sheet material 104 of FIG. 1B.Preferably, frame 1106 is made of material 108 of FIG. 1B. The frame maycomprise one or more layers of polymer. The frame may be continuous ordiscontinuous. Inner layer preferably comprises material 109 comprisingthe agent 102, as examplified in FIG. 1B.

Reference is now made to FIG. 12A-12E, which shows perspective side viewof an essentially planar device 1200 also produced by the method of FIG.1B, in accordance with another preferred embodiment of the presentinvention. As shown, external layers 1202 and 1208 are sealed (to becomepermeable to the agent only upon wetting) and enclose a frame 1206housing an array of compartments 1210 construed from segments 1206 eachcompartment carrying an agent-releasing formulation in separate segments1204. The dimensions, provided in the figure in millimeters, should beconstrued to be illustrative but not limiting. In accordance with thisspecific embodiment, device 1200 comprises two outer layers, upper outerlayer 1202 and lower outer layer 1208. A frame 1206 is mounted on lowerlayer 1208 and inner layer segments 1204 are inserted into the frame1206. The upper layer 1202 is then mounted onto the frame 1206 and ontoinner segments 1204.

FIG. 13A-13B show, respectively a side view and cross-sectional view ofan encapsulated folded device 1300 produced by the method of FIG. 1B, inaccordance with a preferred embodiment of the present invention.Encapsulated delivery device comprises a capsule 1302 comprising acapsule base 1304 and a cap 1306, wherein the cap is verticallymountable to form an overlapping region 1308 in close-fit associationwith the capsule base.

A folded device 1310 placed in capsule 1302 may be similar or identicalto dosage form 182 of FIG. 1B. Typically, folding is such so that theprojection of the folded device has an area of less than 50%, preferablyless than 30% and at times even less than 20% of the unfolded device172. The dimensions, provided in the figure in millimeters, should beconstrued to be illustrative but not limiting.

In some embodiments, the folded device, is typically folded parallel tothe width of the unfolded device and designed to have folds which aresymmetric mirror images about a first axis 1312 and having folds ofincreasingly smaller amplitudes 1314, 1316, 1318 upon extending awayfrom the first axis, such that upon inducing a force from two ends of asecond axis 1320 perpendicular to the first axis, the folded device ispressed to attain an at least partially circular cross-section 1322 foreasy insertion into capsule 1302.

It is appreciated that certain features of the invention, which are, forclarity, described in the context of separate embodiments, may also beprovided in combination in a single embodiment. Conversely, variousfeatures of the invention, which are, for brevity, described in thecontext of a single embodiment, may also be provided separately or inany suitable sub combination.

Although the invention has been described in conjunction with specificembodiments thereof, it is evident that many alternatives, modificationsand variations will be apparent to those skilled in the art.

All publications, patents and patent applications mentioned in thisspecification are herein incorporated in their entirety by referenceinto the specification.

1. A method for producing an agent delivery device for oral intakecomprising: (i) assembling one or more layers comprising one or morematerials with an agent or an agent-releasing formulation to form anintergraded device; (ii) folding said integrated delivery device to forma folded integrated delivery device; and (iii) at least partiallyenclosing said folded delivery device to a form suitable for oraldelivery.
 2. The method as claimed in claim 1, wherein said one or morelayers comprise one or more polymeric materials.
 3. The method asclaimed in claim 2, wherein said one or more layers comprises a singleor a combination of polymers, the polymer or polymers in each layer maybe the same or different from that of another layer within the device.4. The method as claimed in any one of claims 1 to 3, comprising atleast one layer in the form of a strip attached to at least one of saidone or more layers.
 5. The method as claimed in any one of claims 1 to4, wherein at least one of said one or more layers comprise said agentor agent releasing formulation.
 6. The method as claimed in claim 5,wherein said at least one of said one or more layers comprising theagent or agent-releasing formulation, comprises one or more compartmentscomprising said agent or agent-releasing formulation.
 7. The method asclaimed in any one of claims 1 to 6, wherein said assembling comprisesintegration of said one or more layers to form a laminated device. 8.The method as claimed in any one of claims 1 to 7, comprising assemblingtwo external layers made of a first material and sandwiching afunctional layer, the functional layer comprising at least one layer ina form of a strip or plurality of strips made of a second material andcomprising the agent or agent-releasing formulation.
 9. The method asclaimed in claim 8, wherein said functional layer comprises a matrixcomprising the agent or agent releasing formulation of a one or morelayers, each layer comprising one or more compartments comprising saidagent or agent-releasing formulation.
 10. The method as claimed in claim9, wherein said agent or agent-releasing formulation is releasable fromthe matrix or from the compartments.
 11. The method as claimed in claim9 or 10, wherein said matrix comprises a polymeric composition.
 12. Themethod as claimed in any one of claims 1 to 10, comprising assembling atleast one layer of an enforcing polymeric composition having amechanical strength such that upon unfolding of the delivery device, theenforcing polymeric composition enables retention of the device in anessentially unfolded configuration.
 13. The method as claimed in claim12, wherein said layer of the enforcing polymeric composition isprovided in the form of one or more continuous or non-continuouspolymeric strips, said continuous strip optionally comprises one or moregaps, depressions or slits.
 14. The method as claimed in claim 13,wherein said layer of the enforcing polymeric composition is in the formof a continuous frame at said device's periphery.
 15. The method asclaimed in any one of claims 4 to 14, comprising assembling at least onelayer in a form of one or more continuous or non-continuous strips withone or more layers comprising said agent or agent-releasing formulation.16. The method as claimed in any one of claims 4 to 15, wherein saidstrips are in the form of a frame having inner boundaries defining avoid, and the method comprises assembling said frame with one or morelayers comprising said agent or agent-releasing formulation, such thatthe one or more layers comprising the agent or agent-releasingformulation is affixed, attached or integrally formed within said void.17. The method as claimed in any one of claims 4 to 14, wherein saidstrips are in the form of a frame having inner boundaries defining avoid, the method comprising assembling said frame with anagent-releasing formulation, such that the agent-releasing formulationis enclosed within said void.
 18. The method as claimed in any one ofclaims 1 to 17, wherein said integrated device comprises two or morelayers, and said assembling comprises one or more of or a memberselected from adhering, welding, curing or fusion of the two or morelayers so as to allow integration between the same.
 19. The method asclaimed in claim 18, comprising applying an integration agent to saidtwo or more layers so as to facilitate integration between the layers.20. The method as claimed in claim 19, wherein said integration agent isan adhering agent.
 21. The method as claimed in claim 19 or 20,comprising applying said integration agent by spraying onto at least aportion of said one or more layers.
 22. The method as claimed in any oneof claims 1 to 21, wherein said assembling comprises at least one of thefollowing: embedding said agent or agent releasing formulation into oneor more layers; trapping said agent or agent releasing formulationwithin at least two layers; enveloping said agent or agent-releasingformulation within at least one polymeric membrane segment; attachingsaid agent or agent-releasing formulation to or in at least one of saidone or more layers of the device, nano- or microparticles, powder,liquid or compressed solids or a matrix.
 23. The method as claimed inany one of claims 1 to 22, comprising assembling two or more layers ofthe same or different material.
 24. The method as claimed in claim 23,comprising assembling a laminated device comprising two external layersmade of a first material and sandwiching one or more layers comprisingone or more strips made of a second material and comprising the agent oragent-releasing formulation.
 25. The method as claimed in claim 24,wherein at least one of said external layers is perforated or assumesperforations upon wetting.
 26. The method as claimed in any one ofclaims 1 to 25, wherein said folding comprises manipulation of saidintegrated device into a compacted integrated device which is at leastfive times less in dimension than that of the integrated device prior tosaid folding.
 27. The method as claimed in claim 1, comprisingassembling at least four layers, said at least four layers comprising:(i) two first, essentially planar, polymeric sheet portion having outerboundaries and comprising a first polymeric material; (ii) a second,essentially planar, polymeric sheet portion comprising a secondpolymeric material; said second polymeric sheet defining frame withouter boundaries and inner boundaries, the outer boundaries being ofessentially the same shape as the outer boundaries of the firstpolymeric sheet portion and the inner boundaries defining a void area;(iii) a third, essentially planar, polymeric sheet portion comprisingsaid agent or agent-releasing formulation releasable from said sheetwhen wetted, said sheet having outer boundaries to fit within the voidarea; wherein the four sheet portions are assembled such that the thirdsheet portion is within the void area formed from the second sheetportion and the said second sheet portion and third sheet portion beingjointly sandwiched between the two first polymeric sheet portions, withall outer boundaries essentially overlapping one another.
 28. The methodas claimed in claim 28, wherein said assembly provides a laminateddevice.
 29. The method as claimed in any one of claims 1 to 28, whereinsaid folding comprises: placing said integrated device in between twoopposite faces of a press, each face having a corrugated surface withridges of one corrugated surface being essentially opposite to troughsof the other corrugated surface and essentially fitting one into theother; and pressing the two opposite faces one versus the other suchthat an undulated, three dimensional device is formed with undulationsthat correspond in shape to that of said corrugated surfaces.
 30. Themethod as claimed in claim 29, wherein said folding comprises applying apress so as to push sides of the undulated device in a directionperpendicular to said undulation, into a folded device having foldsformed along ridges and troughs of the undulation.
 31. The method asclaimed in any one of claims 1 to 30, wherein said at least partiallyenclosing comprises at least one of a member selected from wrapping,dipping, spraying, encapsulating, binding, tying, molding, envelopingand sealing.
 32. The method as claimed in claim 31, wherein saidencapsulating comprises placing the folded device into a capsule baseand fitting a cap of said capsule onto the capsule base so as to form anencapsulated folded delivery device.
 33. The method as claimed in anyone of claims 1 to 32 for producing a gastro-retentive oral deliverydevice.
 34. The method as claimed in any one of claims 1 to 33, forproducing a delivery device with controlled release of the agent.
 35. Asystem for producing an agent delivery device for oral intakecomprising: (i) an assembly apparatus adapted to assemble one or morelayers comprising one or more materials and an agent or anagent-releasing formulation to form an intergraded device; (ii) afolding apparatus adapted to fold the integrated device into a foldedintegrated device; (iii) an enclosing apparatus adapted to at leastpartially enclose the folded integrated device within an enclosure toform a device in a form suitable for oral delivery.
 36. The system asclaimed in claim 35, wherein said assembling apparatus is adapted toassemble an integrated device, the integrated device comprising: (i) afirst external layer comprising a first material; (ii) one or morefunctional layers mounted on said first external layer and comprising asecond material and said agent or agent releasing formulation; (iii) asecond external layer comprising said first material and mounted on saidfunctional layer.
 37. The system as claimed in claim 36, wherein saidassembling apparatus is adapted to assemble an integrated device, theintegrated device comprising: (i) a first external layer comprising afirst material; (ii) a frame mounted on said first external layer andcomprising a second material, said frame having inner boundariesdefining a void area; (iii) an agent or agent releasing formulationenclosed within said void area; (iv) a second external layer comprisingsaid first material and mounted on said frame.
 38. The system as claimedin claim 36 or 37, wherein said assembly apparatus is adapted toassemble said agent or agent releasing formulation when said agent oragent releasing formulation is embedded into one or more layers; trappedwithin at least two layers; enveloped within at least one polymericmembrane segment; attached to or in any one of at least one layer of thedevice, nano- or microparticles, powder, liquid or compressed solids orto or in a matrix.
 39. The system as claimed in any one of claims 36 to38, wherein said assembling apparatus comprises a dicing apparatusadapted to cut at least one shaped piece from a sheet from a firstmaterial and at least one shaped piece from a sheet of a secondmaterial.
 40. The system as claimed in any one of claims 36 to 39,comprising an application apparatus adapted to apply an integrationagent onto at least one of the devices layers prior to the assembly. 41.The system as claimed in claim 40, wherein said application apparatuscomprises a sprayer for spraying said integration agent onto at leastone of the devices layers.
 42. The system as claimed in any one ofclaims 36 to 41, wherein said assembly apparatus is adapted to provide alaminated device by adhering, welding, curing, or fusing of the device'slayers.
 43. The system as claimed in any one of claims 36 to 44,comprising a perforation apparatus adapted to provide at least one ofsaid external layers with a plurality of perforations.
 44. The system asclaimed in any one of claims 36 to 43, comprising a coating apparatusadapted to provide a coat onto at least one side of the integrateddevice.
 45. The system as claimed in claim 44, wherein said coatingapparatus is adapted to provide powder coating following folding of theintegrated device.
 46. The system as claimed in any one of claims 36 to45, wherein said folding apparatus comprises a press with two oppositefaces, each face having a corrugated surface with ridges of onecorrugated surface being essentially opposite to troughs of the othercorrugated surface and essentially fitting one into the other; wherebyupon placing the integrated device in the press and pressing the twoopposite faces one versus the other an undulated, three dimensionaldevice is formed with undulations that correspond in shape to that ofsaid corrugated surfaces.
 47. The system as claimed in claim 46, whereinsaid folding apparatus is adapted to press the undulated device in adirection perpendicular to the undulations so as to form a folded devicehaving folds formed along ridges and troughs of the undulation.
 48. Thesystem as claimed in any one of claims 36 to 47, wherein said enclosingapparatus comprises a capsule jig for holding a capsule base and thesame or different capsule jig for holding a capsule cap, whereby uponinsertion of the folded integrated device into said capsule base, saidcapsule cap is fitted onto said capsule base comprising the foldedintegrated device.
 49. An agent delivery device for oral intakecomprising a folded single or multi-layered integrated device comprisingan agent or agent releasing formulation, the folded integrated devicebeing at least partially enclosed within or by an enclosure, said agentdelivery device being prepared by the method as claimed in any one ofclaims 1 to
 35. 50. The oral agent delivery device as claimed in claim49, wherein said integrated device comprises a folded multi-layeredlaminated device enclosed within a capsule.
 51. The oral agent deliverydevice as claimed in claim 49 or 50 for controlled, gastroretentivedelivery of said agent.
 52. A folding apparatus for folding a single ormulti-layered sheet comprising a primary press with two opposite faces,each face having a corrugated surface with ridges of one corrugatedsurface being essentially opposite to troughs of the other corrugatedsurface and essentially fitting one into the other; whereby upon placingat least a portion of the single or multi-layered sheet in the primarypress and pressing the two opposite faces one versus the other a threedimensional device is formed with undulations that correspond in shapeto that of said corrugated surfaces.
 53. The folding apparatus asclaimed in claim 52, wherein said corrugated surface is formed by aseries of fingers comprising a movable central finger having a firstlength, and at least one pair of secondary movable fingers siding saidcentral finger and having a second length being shorter than the firstlength, the folding apparatus further comprising a control utility forcontrolling upwardly and downwardly movement of said central finger andat least one pair of secondary fingers towards the said other corrugatedsurface.
 54. The folding apparatus of claim 53, comprising a movablecentral finger having a first length, at least one pair of secondarymovable fingers siding said central finger and having a second lengthbeing shorter than the first length, and a pair or outer movable fingershaving a third length being shorter than the second length, each outerfinger siding one of the secondary fingers.
 55. The folding apparatus asclaimed in claim 53 or 54, wherein said control utility if forcontrolling sequential upwardly and downwardly movement of said fingers.56. The folding apparatus as claimed in any one of claims 52 to 55,comprising a secondary press having opposite faces perpendicular to theundulations formed in the device following operation of the primarypress, such that activation of said secondary press provides a foldeddevice having a dimension which is at least five times smaller than thatof the sheet prior to pressing.
 57. A method for folding a single ormulti-layered sheet comprising: (i) placing said sheet in a foldingapparatus as claimed in any one of claims 52 to 55; (ii) pressing thetwo opposite faces of the first press one versus the other to form anundulated, three dimensional device with undulations that correspond inshape to that of said corrugated surfaces.
 58. The method as claimed inclaim 56, comprising activating a secondary press so as to press theundulated device in a direction perpendicular to the direction ofpressing by said first press so as to obtain a folded device having adimension which is at least five times smaller than that of the sheetprior to pressing.